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The Hall–Héroult process is the major industrial process for smelting aluminium. It involves dissolving aluminium oxide (alumina) (obtained most often from bauxite , aluminium 's chief ore, through the Bayer process ) in molten cryolite and electrolyzing the molten salt bath, typically in a purpose-built cell.
Alumina is extracted from the ore bauxite by means of the Bayer process at an alumina refinery. This is an electrolytic process, so an aluminium smelter uses huge amounts of electric power; smelters tend to be located close to large power stations, often hydro-electric ones, in order to hold down costs and reduce the overall carbon footprint ...
Hall and Heroult share credit for inventing aluminium electrolysis. [9] The Hall–Heroult method is the primary method of producing modern aluminium and requires high purity alumina to produce aluminium. The Bayer process produces high purity alumina which is then used in the Hall–Heroult process as the main raw material. [9]
Aluminium recycling is the process in which secondary commercial aluminium is created from scrap or other forms of end-of-life or otherwise unusable aluminium. [1] It involves re-melting the metal, which is cheaper and more energy-efficient than the production of virgin aluminium by electrolysis of alumina (Al 2 O 3 ) refined from raw bauxite ...
[h] Hall co-founded the Pittsburgh Reduction Company in 1888 and initiated production of aluminium. [88] Hall's patent was granted in 1889. [74] [i] In 1889, Hall's production began to use the principle of internal heating. [j] By September 1889, Hall's production grew to 385 pounds (175 kilograms) at a cost of $0.65 per pound. [91]
The bauxite is processed and transformed using the Bayer process into alumina, which is then processed using the Hall–Héroult process, resulting in the final aluminium. Aluminium production is highly energy-consuming, and so the producers tend to locate smelters in places where electric power is both plentiful and inexpensive. [ 139 ]
The Bayer process is the principal industrial means of refining bauxite to produce alumina (aluminium oxide) and was developed by Carl Josef Bayer.Bauxite, the most important ore of aluminium, contains only 30–60% aluminium oxide (Al 2 O 3), the rest being a mixture of silica, various iron oxides, and titanium dioxide. [1]
This process involved dissolving the aluminum oxide out of the bauxite mineral to produce gibbsite, which can then be purified back into raw alumina. The Bayer process and the Hall-Héroult process are still used today to produce a majority of the world's alumina and aluminum. [21]
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